Dr. R. T. Patil, Ex Director CIPHET, Ludhiana; Group Director, TIT-

MBA, and Director, Technocrats Institute of Technology, Chairman Benevole for PHT

Bhopal (MP), India

POST HARVEST TECHNOLOGY-HERBINGER OF NATIONS PROSPERITY

Production & Post Harvest Scenario

•Agriculture contributes about 14.5% of GDP,employees 57% workforce and sustains approxover 75% of the population

•India produces about 257.44 million tons of foodgrains and 267 million tons of fruits andvegetables and ranks second in the world

•Post harvest losses are 3-18% amounting to Rs.45000 crores

•Low level of processing of fruits and vegetablesat only 2% .

•Food processing is employment intensive,creates 1.8 jobs directly and 6.4 indirectly forevery Rs. 10 lakh investment

Price Difference Wheat - Rs 12/kg Wheat Flour Rs. 16-18/kg

Fortified Flour Rs. 20-25/kg

Oil seed – Rs 35/kg Oil Rs. 70/kg

Paddy – Rs 12/kg Rice – Rs. 25/kg

Mung- Rs. 20/kg Mung dal – Rs. 60/kg

Maize-Rs.13/kg Maize flour-Rs. 16/kg

Tomato-Rs. 5/kg Tomato ketchup-Rs 50-80/kg

Fruit- Rs. 15-20/kg Fruits Bar-Rs. 200/kg

Fruit Juice- Rs. 35/litre

Coriander -Rs. 80/kg Coriander Powder-Rs. 200/kg

Turmeric-Rs.65/kg Turmeric Powder –Rs. 200/kg

Chili- Rs. 200/kg Chili Powder-Rs. 300/kg

Black pepper-Rs. 100/kg B Pepper Powder- Rs.300/kg

Chana - Rs. 28/kg Chana Dal-Rs. 35/kg

Besan- Rs. 40/kg

Vegetables-Rs.3-5/kg Minimal Processed/Ready to Cook

Rs. 25-30/kg

High Value Products from Wastes

• Pectin from fruit and vegetable peels

• Lycopene from tomato peel and oil from seeds

• Bio-colour from arhar husk and used flowers

• A low calorie sweetner (xyletol) from corn cob and

bagasse

• Beta amylase and Xylanase from cereal bran and husk

• Enzymes (protease, laccase, peroxidase and polyphenol

oxidase) from green gram husk and wheat germ

• Gelatin / Peptides from slaughter house waste

• Dietary fibres from fruit pomace

• Bio-plastics from tapioca

• Aniti oxidents and phenolic compounds from cereal

brans and pulse husks

Reasons for Losses

1. Handling of raw produce through many stages of

middlemen.

2. Processing is mostly controlled by urban rather than rural

entrepreneurs which leads to losses in valuable by

products.

3. Non availability of adequate and efficient equipment and

machinery to be used in catchment areas.

4. Low level of entrepreneurial urge in rural areas due to

constraints of finance, assured market and proper training

on technology

5. On the whole, there exists a fragmented and inefficient

value chain

Higher the processing- - Better the Post Harvest

Management - - Lower Will Be Losses

Post Harvest Activities in SITU

1. Can provide processed food of highest quality at

affordable cost to consumers

2. Help environment by processing food in production

catchment with least food miles

3. Ensure traceability of raw materials used for

processed product hence great for export and elite

urban market.

4. Help effective backward linkage with farmers for

processing their raw produce

5. Shorten the supply chain, increase the profitability of

farmers and ultimately increase in GDP from

agriculture and reduce poverty

6. Reduce post harvest losses and increased

availability of by products for further processing.

Unit Operations in Post Harvest

Management

Food Grains

•Harvesting at Maturity

•Proper threshing

•Post thresh cleaning

•Proper drying

•Safe storage

Fruits and Vegetables

•Preharvest treatment

•Harvesting at Maturity

•Safe harvesting

•Pre cooling & washing

•Surface drying

•Cool/cold storage

•Safe transport

•Safe handling

•Value Addition to Main

& Byproducts

Agro Entrepreneurship

Agro Entrepreneurship

Agro Entrepreneurship

Equipment and

Gadgets

Method of Determining Maturity of

Mango in Tree• Eating quality and postharvest shelf life

of ripe mango depends on its maturity at harvest

• Change of peel color and total soluble solids (TSS) are indicative parameters to measure maturity of mango.

• A maturity index was defined based onTSS and colour values.

• The model was developed to predictmaturity using colourimeter

• Colour and maturity index chart werealso developed to determine maturity

• This technique can be employed tosort the mangoes at export port, bigmandies and in processing plant.

Capacity

About 100 mangoes per hour

Fruit Saving Gadgets

After plucking

from tree, fruit is

thrown in the

trough of fruit

saver and

collected in a

box/container.

The fruits are graded on size basis at

appropriate places. Smallest grade fruit is

collected first and largest grade is collected in

last

Banana-Comb (Hand) Cutter

It is an useful to de-stem the comb from the banana bunch. It

replaces the use of sickle, which was much labor and time

consuming.

It is safe for human and banana hands and can be used for faster

work. 100 to 120 banana bunches can be de-handed per hour.

Saves 10 to 15 banana-fingers per bunch (i. e. 2 to 8 % reduction

in cutting losses of banana fruits)

CIPHET Tomato Grader• The tomatoes roll down the pipes

due to gravity and fall immediatelywherever they find the space of theirdiameter.

• Grades 3: 25-40 mm, 40-55 mm, 55-70 mm and > 70 mm

• The collector is inclined at 10° sothat the tomatoes slide directly incrates.

• The important feature of grader is itsability to adjust the gap between thepipes and inclination of grading tableand hopper.

• It can also be used for other roundfruits and vegetables.

Capacity: of 325 kg/hr

Overall grading efficiency: 66%.

Cost: Rs.25000.00

•Higher aril extraction capacity; around 5.0 quintal per hour

•Aril extraction/separation efficiency is in the range of 90-94%

•Mechanical damage received by arils is only 1-2%

Mechanical Pomegranate Aril Extractor

including Hand Tool

Capacity 10 kg/h

Heat Pump Dryer for High Value

Products

•Micro-processor based temperature

controller to regulates the drying

temperature.

•Minimises the loss of vitamins and

essential oil of the products and save

energy in drying.

•For blanched Amla drying, the dryer

reduced vitamin-C loss up to 87% as

compared to the open sun drying.

•The products such as sliced fruits and

vegetables is dried in 20-25 h and

medicinal herbs and leaf crops are 12-

20 h.

•The cost of the prototype is Rs.

1,50,000 and capacity is 30 kg/batch.

Sitaphal Peeling Machine

Removing the sitaphal seeds and pulp automatically without

disturbing the pulp texture. Capacity: 120Kg/hr, Efficiency: 94%

pulp recovery, Coarse / Intact Pulp recovery: 70-72%; Fine Pulp

recovery: 28-30%. The machine is licensed to NEXTGEN Drying

System, Pune

Emerging

Technologies

Emerging Technologies in Food

Processing

•High Pressure Processing

•Microwave heat processing

•Ohmic heat processing

•Micronisation

•Irradiation

•Extrusion Processing

•Biotechnology

High Pressure Processing

•HPP can replace conventional

processes, while maintaining

safety and quality.

•Effects of HPP are generally

marked as retention of color,

flavor and fresh appearance

Microwave heat processing

•Effective for inactivating enzymes, reduced indirect heating

requirement and water use

•Result in improved product flavour, colour, texture and nutritive

value.

Ohmic heat processing

•Alternating electrical current is passed through a food sample.

•Internal energy generation in foods.

•Produces an inside-out heating pattern at different

frequencies than MW.

•Uniformly heats foods with different densities.

Micronisation

•Short time exposure of electromagnetic radiation at a wavelength

of 1.8-3.4 mm,

•Promotes internal heating and increased digestibility

•Instantized product due to increased ability to uptake of water.

•Starch is gelatinized, seed microstructure becomes more

penetrable and thus short cooking times.

Irradiation

•Gamma - irradiation reduces antinutritional factors

•Reduces the phytic acid content and flatulence causing

oligosaccharides in leguminous crops

•Helps improved keeping quality of food grains and flours

Extrusion Processing

Extruded Products from Coarse Cereals

• Extrusion is a high

temperature short time

processed to produce

expanded & textured

products

• CIPHET has modified the low

cost collet extruder to

produce expanded ready to

eat snacks using rice and

pulse brokens.

• The cost of the unit is Rs 2

Lakh, capacity 25 kg/h, cost

of accessories Rs. 2 lakh and

thus earn about minimum of

Rs. 50,000 per month

Biotechnology

Fermenter of 30 litre capacity with

controls for temperature, pH, DO and

CO2 monitoring installed at CIPHET,

Ludhiana

Bioprocessing Technologies

for Crop Residues

• Efficient process for production of ethanol

• Production of enzymes such as cellulase, xylanase, pectinase and protease

• Production of industrially important products such as citric acid

• Single Cell Protein (SCP) production

Safe Transport

and Storage

Mobile Cool Chamber

• The insulated box was

designed such that it could

hold 8 plastic crates of size

540x360x295 mm in two

layer of four each

• Capacity of storage was

100 kg of fruits with 80%

filling of each plastic crates

• Costs around Rs. 18,000-

20,000/-

Low cost unit saves the fruits from exposure to

sunlight and preserves the quality.

Ventilated Rail Transport

• Ventilated rail cars have been

developed by NHB where the

slotted holes were provided on

front bottom, front and rear ends

to accommodate vertical forced

air and natural convection due to

holes at the bottom.

• At least 15% of total floor area

was perforated and labyrinths

provided for the protection from

rain where ever essential.

• The design provides 5% area at

the bottom and 10% area on the

top at both from and rear ends.

• The rail trasnports the material as

fresh over very long distances

Evaporatively Cooled Room for Storage of Fruits and Vegetables

Compared on the basis of 10%

physiological loss in weight (PLW) the

shelf life inside the room was 34 days

for early kinnow, 23 days for late

kinnow, 11 days for cauliflower and 4

days for spinach as compared to 21,

11, 5 and 2 days respectively in an

ordinary room at the same time.

The cost of the chamber is Rs. 75000 and capacity is 2 tonnes.

•An evaporatively cooled (EC) room (3x3x3m. size) was developed

for on-farm storage of fruits and vegetables.

•The summer temperature inside the EC room was 5-8C lower than

that inside the ordinary room and winter temperature was 5-8 C

higher than that inside the ordinary room.

CIPHET Evaporative Cooled Storage Structure

• Storage of fruits and vegetables

• Evaporatively Cooled Structure (ECS)maintains a moderate low temperatureand sufficiently high relative humidity forshort term storage of fresh fruits andvegetables.

• Advantages

Low level consumption ofelectricity

Less initial investment

Negligible maintenance cost

• Features

– Special design of roof, orientation

– Uses wetted pad as cooling medium

– 20oC below the outside temperature

– An ECS of about 5 -7 tonne storagecapacity may cost about Rs. 1.5 –1.8 lakh.

Technology

Packages

Minimal Processing of Vegetables

Shrink Packaging of Fruits and Vegetables

Storage life

Ambient Cold store

Commodity

Shrink wrapped Unwrapped Shrink wrapped Unwrapped

Kinnow 27 13 70 41

Tomato 19 10 39 23

Capsicum 25 4 46 21

Process Technology for Guava Bar

• Guava is perishable in natureand cannot be stored formore than two days duringpeak season.

• Guava can be processed intoa number of products likefruits bar and beverage

• Fruits, which are rich innutrients can be blended toimprove its acceptability andflavor

• Guava bar acceptable evenafter 6 month of storage

Composition: Moisture: 15%, Vitamin C: 120 mg/100g, Acidity: 1.08%, Reducing sugar: 14%, Non-reducing sugar: 46%, Weight of each bar: 5-10 g, KSM: 0.2%

OSMO-CONVECTIVE DEHYDRATION OF KINNOW SEGMENTS

PROCESS

KINNOW

PEELING

SEPARATING OF SEGMENTS

REMOVAL OF SEEDS

DIPPING IN 60 % SUGAR SYRUP FOR 6 h

DRAINING OF SYRUP

DRIED SEGMENTS

(60 OC FOR 10-12 h)

Ready to Constitute Mustard Saag

•The green leaves are washed, drained

and cut. The cut leaves are taken in the

known proportion.

•The mixture of cut leaves and spices is

cooked and then mashed to get smooth

curry. The curry is then processed

through various steps involving

crushing, cooking, pulping, addition of

edible flour, cold extrusion, drying, size

reduction and packaging to attain

mustard saag powder.

•The dried powder on mixing with

lukewarm / hot water yield the inherent

taste and odor of staple ingredients.

Green chili processing into powder and

puree

•Chilies powder has higher nutrition and

controlled pungency. The green chilies

have more Vitamin C & A and antioxidant

properties.

•About 130 g of green Chilies powder and

300 ml puree could be prepared from one

kilogram of fresh green Chilies.

•The cost of the plant for the processing

200kg of green chilies per day is

estimated at 713000/-.

•The break even point comes be 49.15%

and pay back period 1.91 years

•1kg of green chilies costing Rs. 15/-, the

value added product of Rs. 70/- could be

marketed.

Chili Puree

Green Chili Powder

Ready to Eat Vegetable Blended Meat

Products

Ready to Eat Chicken-Vegetables Sandwich

Ready to Eat Chicken-Vegetables Nuggets

Salient features of this technology are; 1) Utilization

of indigenous equipment, 2) Efficient and economic

use of vegetable by-products, 3) Substantive cost

reduction of chicken products, 4) Improved products

quality, sensory attributes and stability, 5) Low-cost

and low fat chicken products could be prepared and

6) Increase in dietary fiber and natural antioxidants

in the meat products

The major cost factors in the chicken meat

based value added products like fried-

chicken, chicken nuggets are the price of raw

meat, ingredients and imported equipment.

The reduction in cost of production to more

affordable level can be achieved by careful

selection of ingredients, reformulation with

unconventional food ingredients and using

indigenously available equipment.

Use of Kinnow Peels for Face

Care Products

Kinnow Peel Face Pack

Kinnow Peel Face Toner

Kinnow peel is a major (30- 34 %)

processing waste generated during

Kinnow processing into juices.

Rich source of Vitamin C, Carotenoids,

limonene, antioxidants, micronutrients

and antibacterial limonoids.

The face mask/pack and face toner are a

rich blend of major concentration of

Kinnow peel extracts and other minor

components as preservatives and

sticking agents.

The products possess very effective

deep cleansing properties along with

stringent, disinfectant and antiseptic

action to protect facial skin from

unwanted blemishes

Examples

Chowdhary Made Agriculture Profitable

with Value Addition in Rajasthan

Kailash Chaudhary, Age 60 yearsProducts: Aamla juice, amla powder, aloe vera juice, candies, squashes, pickles, sweetsExports to many countriesEmployment: Direct 30;Indirect 40Established: 2004Training and Technologies by CIPHETTurnover: > 1 crore Web: www.ksbiofoods.com

Evaporative Cooled Room

Surinder SinghVill Jalalabad, Moga PunjabProfession: Vegetable Farmer

Cold Room used for on-farm short term storage of fruits and vegetables

Cost of structure: Rs 75,000

Recommendations• Formulate National Post Harvest Management

Policy with incentives for small scale units in rural areas.

• Unleash the vast entrepreneurial talent of our rural population by providing training and credit.

• Forge Public Private partnerships in this sector to develop infrastructure including food parks, cold storage, rural godowns, warehouses etc.

• Facilitate direct marketing by rural entrepreneurs & processors to consumers though modern Haats

• Reach international standards of food packaging, safety and quality and by compulsory appointment of food engg/tech in each food business.

The Post Harvest Industries in Production

Catchment has potential to Provide Urban-

amenities in Rural Areas (PURA) through

employment and income generation for the

youth.